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Sogeti High Tech GmbH, Hein-Sass-Weg 38, D-21129 Hamburg
Hyperworks in the Analysis and Optimization of Composite Structures
Ersteller: Markus LongeruE-Mail: [email protected]: 02. November 2009
ALTAIR 3rd European HTC – Ludwigsburg November 2nd- 4th, 2009
Markus Longeru Volker GrundTechnical Leader Stress Engineer
AbstractThe presentation ‚Hyperworks in the Analysis and Optimization of Composite Structures‘ provides an overview of the use of ALTAIR software applications in engineering supplier tasks.The presentation shows the main fields of activities, where ALTAIR products lead to advantages by means of calculation quality and project performance. On the exemplary projects, that have been performed by SOGETI HighTech, such as meshing an AIRBUS wing cover, calculate vibration and shock of a ship antenna, optimizing military antenna structures made of GFRP and secondary aircraft structure made of CFRP the application for various industries with their specific problems and solutions will be shown.For the wing cover, a detailed FE model of shell elements is generated, which needed a high grade of automation due to a large model with a high amount of elements and special demands. The ship antenna is an interesting example for the postprocessing of shock analysis while the military antenna structure, made of GFRP has been optimized regarding its weight using topology- as well as composite optimization tools.Finally, for the secondary structure example, a pilot project from Sogeti HighTech will be discussed where a metallic bracket has been transformed to CFRP. Within the project the bracket has been sized, manufactured and tested. On this example the whole process from structural concept, pre-dimensioning, optimization and test calculation will be shown.
Sogeti High Tech GmbH, Hein-Sass-Weg 38, D-21129 Hamburg 2
Introduction
Agenda
Sogeti High Tech
Technical
Advantages
Summary & Conclusions
IntroductionAgenda
Sogeti High Tech
TechnicalWorkflow and Tools
Pre-processing
Solver
Post-processing
Optimization
AdvantagesTechnical View
Commercial View
Summary & Conclusions
Markus LongeruTechnical LeaderAnalytical & Numerical [email protected]
Hyperworks in the Analysis and Optimization of Composite Structures
Introduction -Agenda
Sogeti High Tech GmbH, Hein-Sass-Weg 38, D-21129 Hamburg 3
Introduction -Sogeti HighTech
Introduction
Agenda
Sogeti High Tech
Technical
Advantages
Summary & Conclusions
Markus LongeruTechnical LeaderAnalytical & Numerical [email protected]
Hyperworks in the Analysis and Optimization of Composite Structures • 83.500 Employees
• 8,7 Billion €• worldwide
• 20.000 Employees
15 countries, with 200+ local offices
Sweden
SwitzerlandSpain
FranceBenlux
The Netherlands
U.S.A.
Ireland
DenmarkUnited Kingdom
India
• 3.500 Employees• 9 Countries
• 350 Employees• focus on fix price projects• 8 locations• EN(AS) 9100; DIN EN ISO 9001:2000
Sogeti High Tech GmbH, Hein-Sass-Weg 38, D-21129 Hamburg 4
Introduction
Agenda
Sogeti High Tech
Technical
Advantages
Summary & Conclusions
Markus LongeruTechnical LeaderAnalytical & Numerical [email protected]
Hyperworks in the Analysis and Optimization of Composite Structures
Activities
• Numerical Simulation
• DMU and Simulation
• Design and Drafting
• Jigs and tools
• Quality management
• Testing
Introduction -Sogeti HighTech
General Information
• Engineering Services focused on the Aerospace-, Transportation-, Energy- and Machinery Industry
• Team of more than 350 skilled engineers, designers and draftsmen
• Certified EADS E2S-Supplier
• Certified Airbus 1.Level-Supplier (BSF 006)
Optimization
Post-Processing
Solving
Pre-Processing
Sogeti High Tech GmbH, Hein-Sass-Weg 38, D-21129 Hamburg 5
Introduction
Technical
Workflow & Tools
Pre-Processing
Solver
Post-Processing
Optimization
Advantages
Summary & Conclusions
Markus LongeruTechnical LeaderAnalytical & Numerical [email protected]
Hyperworks in the Analysis and Optimization of Composite Structures
Technical -Workflow & Tools
Preparation of Geometry
Meshing
Loads and Boundaries
FE Calculation
Evaluation of Results
Update Mesh
HyperMeshPATRANCARDS (Intern Tool)
NASTRANABAQUSANSYSRADIOSS
Hyper View EXCELPATRAN CARDSFemFatISAMI
CAD-Data
CATIASolid Works
Sogeti High Tech GmbH, Hein-Sass-Weg 38, D-21129 Hamburg 6
Markus LongeruTechnical LeaderAnalytical & Numerical [email protected]
Hyperworks in the Analysis and Optimization of Composite Structures
Technical -Pre-Processing
Preparation of Geometry
Brackets – Metallic and Composite
Generation of Midsurfaces- Advanced tools for midsurface manipulation
- Connect Midsurfaces- Convert radii to corners
- Automated property definition- Using the midsurface option
Hypermesh ‘keeps the thickness in mind‘ and can assign it automatically to the elements
Introduction
Technical
Workflow & Tools
Pre-Processing
Solver
Post-Processing
Optimization
Advantages
Summary & Conclusions Defeaturing
- Close small holes- Eliminate radii -> Edge / Surf Fillets
Sogeti High Tech GmbH, Hein-Sass-Weg 38, D-21129 Hamburg 7
Markus LongeruTechnical LeaderAnalytical & Numerical [email protected]
Hyperworks in the Analysis and Optimization of Composite Structures
Technical -Pre-Processing
Meshing and Property definition
Introduction
Technical
Workflow & Tools
Pre-Processing
Solver
Post-Processing
Optimization
Advantages
Summary & Conclusions
Detailed Model of Test Specimen
Skin
Spar
Ribs
Generate Midsurface
Mesh generation respecting ramps and geometric contours
Automated PCOMP Extraction from CATIA(1 Prop per Elm)
TCL Scripting for generating property sets(delete redundancies)
Sogeti High Tech GmbH, Hein-Sass-Weg 38, D-21129 Hamburg 8
Markus LongeruTechnical LeaderAnalytical & Numerical [email protected]
Hyperworks in the Analysis and Optimization of Composite Structures
Technical -Pre-Processing
TCL Scripting Tasks• Generate stringer foot elements
• Double elements
• Duplicate global nodes and renumbering
• Offset stringer blade by RBE2 Elements•Offset equal to average thickness of surrounding skin elements
Introduction
Technical
Workflow & Tools
Pre-Processing
Solver
Post-Processing
Optimization
Advantages
Summary & Conclusions
CFRP Wing Cover
Structure
Idealization
Model Size• 33 Ribs• 19 Stringer•115000 Elements
Sogeti High Tech GmbH, Hein-Sass-Weg 38, D-21129 Hamburg 9
Markus LongeruTechnical LeaderAnalytical & Numerical [email protected]
Hyperworks in the Analysis and Optimization of Composite Structures
Technical -Pre-Processing
Data Consintency
Introduction
Technical
Workflow & Tools
Pre-Processing
Solver
Post-Processing
Optimization
Advantages
Summary & Conclusions
Input / Output- Comments and entries that are not known by Hypermesh are kepf in the .bdf
- are moved to the end of the file
- .bdf files become very large due to Hypermesh comments
- can be swiched off in V10
Components from geometry file- Components are automatically generated
- By Hypermesh comment - By Property- By One component
Sustain file structures- Include structure can be conserved
Property IDs- Division Hypermesh ID / Solver ID
- may be different- may lead to user errors
Sogeti High Tech GmbH, Hein-Sass-Weg 38, D-21129 Hamburg 10
Markus LongeruTechnical LeaderAnalytical & Numerical [email protected]
Hyperworks in the Analysis and Optimization of Composite Structures
Technical -Pre-Processing
Pre-Processing Evaluation
Introduction
Technical
Workflow & Tools
Pre-Processing
Solver
Post-Processing
Optimization
Advantages
Summary & Conclusions
Quality Performance
Precise Geometry Data
Good Mesh Quality
Less errors due to routines
Fast GUI -> Needs Training
High Level of Adaptivity
Relatively fast Geometry update
Low effort for midsurface modification before meshing
Fast thickness definition for isotropic properties or PSHELL idealization
Scripting for repetitive tasks
Fast adaption of geometry updates with morphing function
Sogeti High Tech GmbH, Hein-Sass-Weg 38, D-21129 Hamburg 11
Markus LongeruTechnical LeaderAnalytical & Numerical [email protected]
Hyperworks in the Analysis and Optimization of Composite Structures
Technical -Solver
Compatibility to various solvers
Introduction
Technical
Workflow & Tools
Pre-Processing
Solver
Post-Processing
Optimization
Advantages
Summary & Conclusions
Conversion of NASTRAN Models to ABAQUS
Solver –Independant software package-> Good fit to all types of solvers
Problems Hypermesh V9:
NASTRAN RBE3 toABAQUS DCOUP3D
Sogeti High Tech GmbH, Hein-Sass-Weg 38, D-21129 Hamburg 12
Markus LongeruTechnical LeaderAnalytical & Numerical [email protected]
Hyperworks in the Analysis and Optimization of Composite Structures
Technical -Post-Processing
Static Analysis
Introduction
Technical
Workflow & Tools
Pre-Processing
Solver
Post-Processing
Optimization
Advantages
Summary & Conclusions
Static analysis of CFRP structures are mostly performed using own Java Tool package due to
- Automation- Number of LC- Individual content of result tables- Easy implementation of arbitrary failure criteria- etc.
Results for composite Justification:
Element Forces (Fluxes)- In Material Axes
Element Strains- In Material Axes
Free-Body Forces
Sogeti High Tech GmbH, Hein-Sass-Weg 38, D-21129 Hamburg 13
Markus LongeruTechnical LeaderAnalytical & Numerical [email protected]
Hyperworks in the Analysis and Optimization of Composite Structures
Technical -Post-Processing
Dynamics
Military Ship Antenna
Weight Optimization at best structural Performance at
• Wind Loads
• Movement of the Ship
• Shock
• Vibration
• Top Load of 50kg
Introduction
Technical
Workflow & Tools
Pre-Processing
Solver
Post-Processing
Optimization
Advantages
Summary & Conclusions
Sogeti High Tech GmbH, Hein-Sass-Weg 38, D-21129 Hamburg 14
Markus LongeruTechnical LeaderAnalytical & Numerical [email protected]
Hyperworks in the Analysis and Optimization of Composite Structures
Technical -Post-Processing
Dynamics
Military Ship Antenna
10 times deformation scale15 time steps [0s, 0.9s]
0 times deformation scale15 time steps [0s, 0.9s]von Mises stresses
Displacements per Timestep Stresses per Timestep
Shock 120g for 15msIntroduction
Technical
Workflow & Tools
Pre-Processing
Solver
Post-Processing
Optimization
Advantages
Summary & Conclusions
Sogeti High Tech GmbH, Hein-Sass-Weg 38, D-21129 Hamburg 15
Markus LongeruTechnical LeaderAnalytical & Numerical [email protected]
Hyperworks in the Analysis and Optimization of Composite Structures
Technical -Post-Processing
Post-Processing Evaluation
Introduction
Technical
Workflow & Tools
Pre-Processing
Solver
Post-Processing
Optimization
Advantages
Summary & Conclusions
Quality Performance
Good result quality for isotropiy materials(v.Mises, etc)
Impossible to relate results to material coord system(Composite Materials)
TCL differs from HyperMesh
Large result files can be handeled
Interface to partner Products (FEMFAT)
Limited Adaptivity for own justification criteria
FEMFAT Plot
Sogeti High Tech GmbH, Hein-Sass-Weg 38, D-21129 Hamburg 16
Markus LongeruTechnical LeaderAnalytical & Numerical [email protected]
Hyperworks in the Analysis and Optimization of Composite Structures
Technical -Optimization
Optimizing Composites
Weight Optimization of Aircraft Primary Structure
Primary Structure made of Foam Sandwich
Model:
Foam and Booster idealized with CHEXA8,
CPENTA, CTETRA Elements
CFRP Covers idealized with CQUAD4 Elements
Introduction
Technical
Workflow & Tools
Pre-Processing
Solver
Post-Processing
Optimization
Advantages
Summary & Conclusions
Sogeti High Tech GmbH, Hein-Sass-Weg 38, D-21129 Hamburg 17
Markus LongeruTechnical LeaderAnalytical & Numerical [email protected]
Hyperworks in the Analysis and Optimization of Composite Structures
Technical -Optimization
Optimizing Composites
Weight Optimization of Aircraft Primary Structure
Introduction
Technical
Workflow & Tools
Pre-Processing
Solver
Post-Processing
Optimization
Advantages
Summary & Conclusions
Booster
Skin
Core
CTETRA
CPENTA
CHEXA
CQUADModel Created by own Routines
Manual Work (Cleaning) done in Hypermesh
Sogeti High Tech GmbH, Hein-Sass-Weg 38, D-21129 Hamburg 18
Markus LongeruTechnical LeaderAnalytical & Numerical [email protected]
Hyperworks in the Analysis and Optimization of Composite Structures
Technical -Optimization
Optimizing Composites – Free-Size
CFRP Foam Sandwich Structures
Introduction
Technical
Workflow & Tools
Pre-Processing
Solver
Post-Processing
Optimization
Advantages
Summary & Conclusions
Load:Combined Torsion / Bending
Start plies:3 plies (+ 45; 0; -45)
Constraints:Displacement in Tip
Objective:Minimize Mass
0° Plies
45° Plies
-45° Plies
Sogeti High Tech GmbH, Hein-Sass-Weg 38, D-21129 Hamburg 19
Markus LongeruTechnical LeaderAnalytical & Numerical [email protected]
Hyperworks in the Analysis and Optimization of Composite Structures
Technical -Optimization
Optimizing Composites – Ply Optimization
CFRP Foam Sandwich Structures
Introduction
Technical
Workflow & Tools
Pre-Processing
Solver
Post-Processing
Optimization
Advantages
Summary & Conclusions
Initial Sets (Global Ply Ids)
Resultant Thickness per Set
First shot Results for 45° Plys
Constraint: Design Space:3500 με Skin only
Objective:Minimize Mass
Sogeti High Tech GmbH, Hein-Sass-Weg 38, D-21129 Hamburg 20
Markus LongeruTechnical LeaderAnalytical & Numerical [email protected]
Hyperworks in the Analysis and Optimization of Composite Structures
Technical -Optimization
Optimization Evaluation
Introduction
Technical
Workflow & Tools
Pre-Processing
Solver
Post-Processing
Optimization
Advantages
Summary & Conclusions
Quality Performance
Hints for required fibre directions
Essencial hints for patch design
Number of layers needed for applied loads
Calculation time for the given example:Approx. 4-5 hours
Comfortable GUI
Sogeti High Tech GmbH, Hein-Sass-Weg 38, D-21129 Hamburg 21
Markus LongeruTechnical LeaderAnalytical & Numerical [email protected]
Hyperworks in the Analysis and Optimization of Composite Structures
Advantages -Commercial View
Costs
Lower Costs due to
• Time Saving
• Quick Geometry Updates
• Direct way to good mesh quality
• Partner Program
• Licence System
Price Performance Ratio
Constant use of Units required to use Hyperworks effectively
Partner Products
Presently in use at Sogeti High Tech:
FEMFAT
Support
Good and Quick Support
Quick & Effective Answers
Licence System
Stacking
Introduction
Technical
Advantages
Technical View
Commercial View
Summary & Conclusions
Sogeti High Tech GmbH, Hein-Sass-Weg 38, D-21129 Hamburg 22
Summary & Conclusions
Thank You For Your Attention
Questions?
Suggestions?
Please contact:
Markus Longeru Volker Grund
Technical Leader Stress Engineer
Tel.: +49 (0)40 743 60185 Tel.: +49 (0)40 743 60275
[email protected] [email protected]
Introduction
Technical
Gain in Experience
Advantages
Summary & Conclusions
Markus LongeruTechnical LeaderAnalytical & Numerical [email protected]
Hyperworks in the Analysis and Optimization of Composite Structures
Sogeti High Tech GmbH, Hein-Sass-Weg 38, D-21129 Hamburg 23
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Sogeti High Tech GmbH, Hein-Sass-Weg 38, D-21129 Hamburg 24
Markus LongeruTechnical LeaderAnalytical & Numerical [email protected]
Hyperworks in the Analysis and Optimization of Composite Structures
Technical -Pre-Processing
Boundaries & Loads
Introduction
Technical
Workflow & Tools
Pre-Processing
Solver
Post-Processing
Optimization
Advantages
Summary & Conclusions
Stationary Antenna
Definition of Ice and Wind Load
Ice Masses as CONMElements
Wind loads on beam elements as force vectors
Wind loads on surfaces as pressure distributionEquation on spherical coordinates
Sogeti High Tech GmbH, Hein-Sass-Weg 38, D-21129 Hamburg 25
Markus LongeruTechnical LeaderAnalytical & Numerical [email protected]
Hyperworks in the Analysis and Optimization of Composite Structures
Technical -Optimization
Optimizing Composites
Optimization of Stiffener PositionGFRP Radar Dome
Variation of Size and Location of Stiffeners to maximum stiffness
Aim of Optimization:
All Eigenfrequencies >20Hz
Dimensions:
4,5m in Height
3,5m in diameterIntroduction
Technical
Workflow & Tools
Pre-Processing
Solver
Post-Processing
Optimization
Advantages
Summary & Conclusions